U.S. patent application number 11/374640 was filed with the patent office on 2007-09-13 for condenser attachment bracket.
This patent application is currently assigned to DENSO International America, Inc.. Invention is credited to Jason R. Hendry, Nicholas Mazzocco, Ben C. Mullis, Christopher Wisniewski.
Application Number | 20070209372 11/374640 |
Document ID | / |
Family ID | 38477565 |
Filed Date | 2007-09-13 |
United States Patent
Application |
20070209372 |
Kind Code |
A1 |
Mazzocco; Nicholas ; et
al. |
September 13, 2007 |
Condenser attachment bracket
Abstract
A mounting arrangement for a heat exchanger in a vehicle
includes a bracket having a main body. A first portion is secured
to the heat exchanger and a second portion includes a mounting
feature adapted to be secured to another component of the vehicle.
A foot is formed on the first portion of the bracket. The foot
defines an interface surface brazed to the heat exchanger in an
installed position.
Inventors: |
Mazzocco; Nicholas; (Royal
Oak, MI) ; Hendry; Jason R.; (Warren, MI) ;
Wisniewski; Christopher; (Novi, MI) ; Mullis; Ben
C.; (Battle Creek, MI) |
Correspondence
Address: |
HARNESS, DICKEY & PIERCE, P.L.C.
P.O. BOX 828
BLOOMFIELD HILLS
MI
48303
US
|
Assignee: |
DENSO International America,
Inc.
|
Family ID: |
38477565 |
Appl. No.: |
11/374640 |
Filed: |
March 13, 2006 |
Current U.S.
Class: |
62/67 ;
165/69 |
Current CPC
Class: |
F28D 2021/0084 20130101;
F28F 9/002 20130101; F28F 2255/16 20130101 |
Class at
Publication: |
062/067 ;
165/069 |
International
Class: |
F25C 1/18 20060101
F25C001/18; F28F 7/00 20060101 F28F007/00 |
Claims
1. A mounting arrangement for a heat exchanger in a vehicle
comprising: a bracket having a main body including a first portion
secured to the heat exchanger and a second portion including a
mounting feature adapted to be secured to another component of the
vehicle; and a foot formed on the first portion of the bracket, the
foot defining an interface surface brazed to the heat exchanger in
an installed position.
2. The mounting arrangement of claim 1 wherein the heat exchanger
defines a pair of offset lateral walls formed thereon and wherein
the foot nests between the pair of lateral walls in the installed
position.
3. The mounting arrangement of claim 2 wherein the main body
generally defines a first and second end walls connected by a
central wall, wherein the first and second end walls are generally
parallel and offset to each other.
4. The mounting arrangement of claim 3 wherein the central wall is
generally transverse to the first and second end walls.
5. The mounting arrangement of claim 4 wherein the central wall
defines an inboard face engaging the condenser in the installed
position.
6. The mounting arrangement of claim 5 wherein said inboard face of
the central wall is brazed to an outboard face of the
condenser.
7. The mounting arrangement of claim 1 wherein said bracket is
formed of metal.
8. The mounting arrangement of claim 7 wherein said bracket is
formed of extruded aluminum.
9. A mounting arrangement for a heat exchanger in a vehicle
comprising: a bracket having a main body including a first end
portion secured to the heat exchanger, an intermediate portion
secured to the heat exchanger and a second end portion including a
mounting feature adapted to be secured to another component of the
vehicle; and wherein the first end portion and the intermediate
portion are brazed to the condenser in an installed position.
10. The mounting arrangement of claim 9 wherein the first end
portion includes a foot defining an interface surface brazed to the
heat exchanger in an installed position.
11. The mounting arrangement of claim 10 wherein the heat exchanger
defines a pair of offset lateral walls formed thereon and wherein
the foot nests between the pair of lateral walls in the installed
position.
12. The mounting arrangement of claim 11 wherein the first and
second end portions define planar wall portions that are generally
parallel and offset to each other.
13. The mounting arrangement of claim 12 wherein the intermediate
portion defines a central wall is generally transverse to the first
and second planar wall portions.
14. The mounting arrangement of claim 13 wherein the central wall
defines an inboard face engaging the condenser in the installed
position.
15. The mounting arrangement of claim 14 wherein said inboard face
of the central wall is brazed to an outboard face of the
condenser.
16. The mounting arrangement of claim 9 wherein said bracket is
formed of metal.
17. The mounting arrangement of claim 16 wherein said bracket is
formed of extruded aluminum.
18. A method for mounting a bracket to a heat exchanger in a
vehicle comprising: applying brazing material onto a foot defined
on the bracket; locating the foot between a pair of laterally
extending walls formed on the heat exchanger; deflecting the walls
toward each other thereby capturing the foot between the walls; and
subjecting the captured foot and bracket to heat to form a brazed
connection therebetween.
19. The method of claim 18 further comprising: applying brazing
material between an inboard face of the bracket and an outboard
face of the condenser.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to HVAC systems in vehicles
and more particularly to an attachment bracket brazed to a
condenser for a vehicle air conditioner.
BACKGROUND OF THE INVENTION
[0002] In automotive vehicles, it is common to have a climate
control systems to establish and maintain passenger comfort.
Typically, climate control systems consist of separate heating and
cooling systems. Typically, a heat exchanger called a condenser is
included as part of the cooling system for performing heat exchange
with the outside air. Heat exchange may be facilitated by a fan to
cool and condense refrigerant from a gas into a liquid in the
condenser.
[0003] Condensers may be provided with jumper tubes for routing
fluid from the outlet of the condenser to the connection point of
the air conditioning (A/C) plumbing. From the connection point, the
fluid may be routed by the A/C plumbing to a desired location such
as to a receiver for separating refrigerant into a gas and a
liquid. Since heat exchange is desired with the outside air, the
engine compartment of the vehicle is generally used to accommodate
the condenser. In many instances, packaging the condenser within
the engine compartment may bring challenges. Because of these
packaging considerations, it is desirable to mount the condenser
while occupying a small amount of space and using minimal hardware.
What is needed then is a device that facilitates mounting of the
condenser in a small space, reduced the number of parts to
accomplish such mounting, reduced the number of manufacturing steps
involved in the condenser assembly, and provides a more rigid
mounting structure.
SUMMARY OF THE INVENTION
[0004] A mounting arrangement for a heat exchanger in a vehicle
includes a bracket having a main body. A first portion is secured
to the heat exchanger and a second portion includes a mounting
feature adapted to be secured to another component of the vehicle.
A foot is formed on the first portion of the bracket. The foot
defines an interface surface brazed to the heat exchanger in an
installed position.
[0005] According to other features, the heat exchanger defines a
pair of offset lateral walls formed thereon. The foot nests between
the pair of lateral walls in the installed position. The main body
of the bracket generally defines first and second end walls
connected by a central wall. The first and second end walls are
generally parallel and offset to each other. An inboard face of the
central wall may be brazed to an outboard face of the condenser. In
one example, the bracket may be formed of extruded aluminum.
[0006] Further areas of applicability of the present invention will
become apparent from the detailed description provided hereinafter.
It should be understood that the detailed description and specific
examples, while indicating the preferred embodiment of the
invention, are intended for purposes of illustration only and are
not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The present invention will become more fully understood from
the detailed description and the accompanying drawings,
wherein:
[0008] FIG. 1 is a functional diagram depicting various components
of an A/C system of a vehicle according to the present
teachings;
[0009] FIG. 2 is a front view of a condenser including mounting
brackets according to the present teachings;
[0010] FIG. 3 is a perspective view of a mounting arrangement with
a bracket brazed to the condenser according to the present
teachings; and
[0011] FIG. 4 is a cross-sectional view of the condenser and
bracket assembly taken along line 4-4 of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] The following description of the preferred embodiment(s) is
merely exemplary in nature and is in no way intended to limit the
invention, its application, or uses.
[0013] With initial reference to FIG. 1, a block diagram of a
conventional vehicle heating, ventilation and air-conditioning
("HVAC") system is shown and generally identified at reference 10.
A refrigeration cycle of the vehicle HVAC system 10 includes an
air-cooling system 14. The air-cooling system 14 includes a
compressor 16 which draws, compresses, and discharges a
refrigerant. The power of a vehicle engine 20 is transmitted to the
compressor 16 through pulleys 22 and a belt 24. As is well known,
the vehicle engine 20 drives not only the air conditioning
compressor 16 but also such auxiliaries as a generator, a hydraulic
pump for a power steering unit, and a coolant pump via belts and
other power transmitting devices.
[0014] In the refrigeration cycle, the compressor 16 discharges a
superheated gas refrigerant of high temperature and high pressure,
which flows into a condenser 28. Here, heat exchange is performed
with the outside air sent by a cooling fan (not shown), so that the
refrigerant is cooled for condensation. The refrigerant condensed
in the condenser 28 then flows into a receiver 30, in which the
refrigerant is separated into a gas and a liquid. A redundant
liquid refrigerant in the refrigeration cycle is stored inside the
receiver 30.
[0015] The liquid refrigerant from the receiver 30 may be
decompressed by an expansion valve 34 into a gas-liquid double
phase state of low pressure refrigerant. The low pressure
refrigerant from the expansion valve 34 flows into an evaporator 36
by way of an inlet pipe 38. The evaporator 36 is arranged inside an
HVAC case 42 of the vehicle air conditioning system 14. The low
pressure refrigerant flowing into the evaporator 36 absorbs heat
from the air inside the HVAC case 42 during refrigerant
evaporation. An outlet pipe 40 of the evaporator 36 may be
connected to the suction side of the compressor 16, so that the
cycle components mentioned above constitute a closed circuit.
[0016] The HVAC case 42 may form a ventilation duct through which
air-conditioned air is sent into the passenger compartment. The
HVAC case 42 contains a fan 44 which is arranged on the upstream
side of the evaporator 36. An inside/outside air switch box (not
shown) is arranged on the suction side of the fan 44 (the left side
in FIG. 1). The air inside the passenger compartment (inside air)
or the air outside the passenger compartment (outside air) switched
and introduced through the inside/outside air switch box is sent
into the HVAC case 42 by the fan 44.
[0017] The HVAC case 42 may accommodate, on the downstream side of
the evaporator 36, a hot water heater core (heat exchanger) 46. The
heater core 46 includes an inlet pipe 48 and an outlet pipe 50. Hot
water (coolant) of the vehicle engine 20 is directed to the heater
core 46 through the inlet pipe 48 by a water pump 52. A water valve
54 controls the flow volume of engine coolant supplied to the
heater core 46. A radiator 56 and a thermostat 58 further cooperate
to control the temperature of the coolant.
[0018] A bypass channel 60 is formed beside the hot water heater
core 46. An air mix door 62 is provided to adjust the volume ratio
between warm air and cool air that passes through the hot water
heater core 46 and the bypass channel 60, respectively. The air mix
door 62 adjusts the temperature of the air blown into the passenger
compartment by adjusting the volume ratio between the warm air and
cool air.
[0019] Additionally, a face outlet 64, a foot outlet 68, and a
defroster outlet 70 may be formed at the downstream end of the HVAC
case 42. The face outlet 64 directs air toward the upper body
portions of passengers, the foot outlet 68 directs air toward the
feet of the passengers, and the defroster outlet 70 directs air
toward the internal surface of a windshield. The outlets 64, 68 and
70 may be opened and closed by an outlet mode doors (not shown).
The air mix door 62 and the outlet mode doors mentioned above are
driven by such electric driving devices such as servo motors via
linkages or the like. It is appreciated that the components
described in relation to FIG. 1 are merely exemplary. In this way,
the following discussion directed to a mounting arrangement for the
condenser 28 may be adapted for other configurations where mounting
a heat exchanger in a vehicle is necessary.
[0020] As will be described in greater detail with reference to
FIGS. 2-4, a series of brackets 80 are used to securely mount the
condenser 28. In the exemplary configuration illustrated in FIG. 2,
three similar brackets 80 are arranged around a perimeter of the
condenser 28. It is appreciated that one, two or more than three
brackets may alternatively be employed. The brackets 80 are joined
to the condenser 28 by a brazing process. The brazing process
employed herein allows the bracket 80 to be securely joined
directly to the condenser 28 without supplemental fasteners. As a
result, reduced packaging requirements may be achieved. It is
appreciated that while specific reference will be made to one of
the three brackets, the remaining brackets posses the same
characteristics and are secured to the condenser in a similar
fashion. According to the present teachings and more specific
reference to FIGS. 3 and 4, a first end 82 of the bracket 80 is
brazed to the condenser 28. In addition, an intermediate portion 84
of the bracket is similarly brazed to the condenser 28. A second
end 86 of the bracket 80 defines an opening 90 for receiving
fasteners (not shown) for securing the bracket 80 to the radiator
56. A fourth distinct bracket 94 is utilized at a remaining corner
of the condenser 28.
[0021] With continued reference to FIGS. 3 and 4 the bracket 80 and
the mounting arrangement between the bracket 80 and the condenser
28 will be described in greater detail. The bracket 80 generally
defines a main body 100 including a first end wall portion 102, a
second end wall portion 104 and a central wall portion 106. An
extension portion or foot 110 is formed on the first end wall
portion 102. The foot 110 defines an arcuate surface 112 adapted to
mate with the condenser 28 as will be described. The central wall
106 defines an inboard face 116 (FIG. 4) that engages an outboard
face 120 of the condenser 28 in the installed position. The bracket
80 is formed of metal such as extruded aluminum. Other materials
may be used.
[0022] The condenser 28 generally defines a first outer surface 122
and a second outer surface 124. A pair of laterally extending walls
or rails 130 are formed on the first surface 122 and cooperate to
define a channel 132. The channel 132 is operable to receive the
foot 110 of the bracket 80 in a nested relationship in the
installed position. The first surface 122 defines an arcuate
surface 136, complementary to the arcuate 112 surface of the
bracket 80.
[0023] Assembly of the mounting bracket 80 to the condenser 28 will
now be described. At the outset, the foot 110 is located into the
channel 132 between the respective walls 130. Next, the opposing
walls 130 of the channel 132 may be deflected toward each other
thereby clamping the foot 110 between the walls 132 and creating a
compression fit.
[0024] Once the bracket 80 is properly located in the channel 132,
brazing material 140 is then disposed at the interface of the foot
110 and the condenser 28. Specifically, brazing material 140 is
disposed between the arcuate surface 112 of the foot 110 and the
complementary arcuate surface 136 of the condenser 28. Similarly,
brazing material 140 is applied to the interface between the
inboard face 116 of the bracket 80 and the outboard face 120 of the
condenser 28. It is appreciated that the brazing material 140 may
be applied to the respective surfaces prior to locating the foot
110 into the channel 132. While the brazing material 140 is
specifically described as being disposed at the foot 110 and the
central wall 106 of the bracket 80, it is appreciated that the
brazing material 140 may be additionally or alternatively be placed
at other locations on the bracket 80. Once the brazing material 140
is applied, the entire assembly is subsequently brazed through a
heat application such as within a furnace.
[0025] Those skilled in the art will readily appreciate that while
the foot 110 is described as being temporarily held to the
condenser 28 by deforming the opposing walls 130, other methods may
be employed. For example, mechanical or chemical coupling material
such as, but not limited to, wire wrapping may be placed in any
location sufficient to temporarily couple the bracket 80 to the
condenser 28. Furthermore, the channel 132 may be configured to
receive the foot 110 as an interference fit, without the need to
form a compression fit.
[0026] Employing the teachings described and depicted in the
drawings yield advantages such as reduced parts compared to
brackets that are bolted or press-fit to the condenser.
Furthermore, a brazed or welded joint is a more rigid construction
than a bolted joint. Additionally, fewer manufacturing steps are
required since the brackets 80 and condenser 28 are brazed along
with other parts of the condenser 28. Finally, the curved surface
112 of the bracket 80 that interfaces with the curved surface 136
of the condenser 28 provides a consistent, continuous fit that
provides secure holding for the condenser 28.
[0027] Those skilled in the art can now appreciate from the
foregoing description that the broad teachings of the present
invention can be implemented in a variety of forms. Therefore,
while this invention has been described in connection with
particular examples thereof, the true scope of the invention should
not be so limited since other modifications will become apparent to
the skilled practitioner upon a study of the drawings, the
specification and the following claims.
* * * * *